Transformer

ABSTRACT

A transformer comprising a specific combination of a seamless iron core portion having formed a completely closed magnetic path and laminated induction plates formed as a primary and a secondary windings, respectively; and a transformer comprising an auxiliary iron core portion which is smaller than the aforesaid iron core portion and intercrossed to the winding of the aforesaid transformer, and said auxiliary winding wound round the auxiliary iron core being adapted to induce therefrom a required small electric power.

United States Patent 1191 Sato Aug. 27, 1974 [54] TRANSFORMER 3,503,027 3/1970 Olsen 336/212 x -1 Inventor: Ryoda Saw, ohoma-cho, iiillli Z5133; 223,???if.fliijiiiiiiijiiiiiii: 332/515,?

Amagasaki, Japan Filed: Nov. 15; 1972 FOREIGN PATENTS OR APPLICATIONS 335,753 3/1959 Switzerland 336/215 [21] Appl. No.: 306,851 126,553 3/1969 Czechoslovakia 336/212 [30] Foreign Application Priority Data Primary Examiner-Roma Kozma Nov. 29, 1971 Japan 46-95346 Attorney Agent Thomas & Askew [52] US. Cl 336/212, 336/215, 336/223, [57] ABSTRACT I 3136/ 234 A transformer com prising a specific comblnation of a 2 g g fig g fg fg 1 Seamless iron core portion having formed a com. l o are 23 pletely closed magnetic path and laminated induction plates formed as a primary and a secondary windings,

.- respectively; andfa transformer comprising an auxili- [56] References cued ary iron core portion which is smaller than the afore- I UNITED STATES PATENTS said iron core portion and intercrossed to the winding 1,723,840 8/1929 Burnham 336/223 X of the aforesaid transformer, and said auxiliary wind- 1,765,483 6/1930 Cole 336/212 X ing wound round the auxiliary iron core being adapted 2,3 l4,9l2 3/l943 Troy 336/212 X to induce therefrom a required mall electric power 2,870,397 l/1959 Kelley, Jr 336/215 X 3,419,834 12/1968 McKechnie et al..;.'. 336/232 X 4 Claims, 17 Drawing Figures PATENTED I ma l-32551 manor 6 FIG.

FIG.

'FIG. 11"

TRANSFORMER Generally speaking, the present invention relates to an electrical transformer, and especially relates to the transformer constituted by assembling and constructing the winding part and ironcore part.

In this kind of transformer, from the necessity for winding the wire on the iron core, in any case in the laminated iron core or in any iron core member, at least one joint must be provided, and due to the vacant clearance produced in this joint part, the magnetic resistance of the whole iron core increases greatly. The magnetic flux contributing the mutual induction between the primary winding and the secondary winding is thereby reduced and the lowering of the quality of the transformer cannot be avoided.

Further, in the electrical apparatus using this kind of transformer, it is desired that the transformer thereof is made lighter in order to reduce the overall weight electrical apparatus because the transformer occupies appreciable weight percentage as compared to the other electrical parts of the apparatus.

Further, in this kind of transformer, in case of the simultaneous supply of the great electrical power to the plural loads, the secondary winding is previously formed in such a way that it may accomodate with the total number of these capacity and the branch line is drawn out of the midway and supplies divided to each load, or said secondary winding was divided according to the number of loads and supplied to each load. In these cases, when the large electric power relatively little powder is to be supplied for welding, when the large electric power to be supplied to the electrode for welding and the small amount of electric power to be supplied to the control part for controlling said large electric power are supplied dividedly by one transformer, the secondary winding wire for supplying the small electrical power had the large cross sectional area samely as the one of the secondary wire wound on the leg of the iron core for supplying the large electrical power, so that the amount of winding wire increased resulting in economical increase.

The object of this invention is to present the improved transformer of the kind described above, and the transformer of high quality and low loss, in which the iron core part for forming completely closed magnetic path and having no connecting part, the primary winding and the laminated induction plate formed as the secondary winding are assembled in a special way.

Another object of this invention is to present a transform, in which, by improving the construction of the iron core part, it may become light and the average magnetic path is shortened and the efficiency is high.

Another one object of this invention is to present an improved transformer in which the auxiliary iron core smaller than the iron core part is intercrossed to the winding part wound intercrossed to the iron core,'the

auxiliary winding is applied to this auxiliary iron core,

FIG. 1 is a plan view of the transformer according to this invention.

FIG. 2 is a front view of the same.

FIG. 3 is a front view of the constituting part of the iron core used in the transformer shown in FIG. 1.

FIG. 4 is the plan view of the electrical conducting plate of the primary winding of the same above.

FIG. 5 is the plan view of the electrical conducting plate of the secondary winding of the same above.

FIG. 6 is the plan view of the transformer of a second embodiment .of this invention.

FIG. 7 is the front view of the same above.

FIGS. 8 including (1) (4) are the front views of the part constituting the iron core used in the transformer shown in FIG. 6.

FIG. 9 is the plan view of the part constituting the winding of the same described above.

FIG. 10 are drawings for explaining the mode for assembling the transformer described above.

FIG. 11 is the plan view of the transformer of a third embodiment of this invention.

FIG. 12 is the front view of the same above.

FIG. 13 is the front view of the constituting member of the main iron core.

FIG. 14 is the front view of the auxiliary iron core constituting member.

FIGS. 15and 16 are plan views of the constituting member of the main winding of the same above.

FIG. 17 is the plan view of the constituting member of the auxiliary winding of the same above.

The practical embodiment of this invention will be explained in detail referring to the drawings. In general, the transformer of this invention is shown at l, and as shown in FIGS. 1 and 2 it is composed of laminated iron core 3 and the winding part 5.

As shown in FIG. 3, four sides of the laminated iron core 3 are composed of a suitable number of sheets laminated of continuous seamless rectangular thin iron plate 3a having the central rectangular opening 7 punched.

In the construction of the winding part 5, the conducting plate 9 for the primary winding and the conducting plate 11 for the secondary winding are alternately arranged with the interposition of the insulating material (not shown) between these two and are stacked for assembly.

As shown in FIG. 4, in the conducting plate 9 for the primary winding, a pair of rectangular good electrical conducting plates 15, 15, each having central rectangular inner opening 13 punched, are arranged adjacently symmetrically right and left in one plane as shown in the drawing for constituting two electric conducting loops, one end of the parallel adjacent legs 15a, 15a are extended outwards respectively. The forward ends of these extending parts are divided into two lengthwise and form the cut openings 15b, 15b, each connected to the comer of said inner opening l3, l3. Terminals 15c, 15c and 15d, 15d of the primary side are provided at said extended part separated by said cut opening 16b. As shown in FIG. 5, in the construction of the electrical conducting plate 11 for the secondary winding, the inner openings l7, 17 of the same size as said inner openings l3, 13 are punched through the rectangular good electrical conducting plate member having the size corresponding two sheets of said constituting member 15, the central leg 11a positioned between these inner openings 17, 17 is extended outwards as well as the cut openings 1 1b, 11b are formed towards the inner openings 17, 17 from both left and right sides thereof respectively, the terminals 110, 11c and 11d of the secondary side separated by these out openings 11b, 11b, and the two electrical conduct loops having said central leg 11a commonly.

Now, the transformer 1 according to this invention is composed of the combination of the iron core constituting member 3a, and the conducting plates 9, 11 for the primary, secondary windings, next, the order of assembling thereof will be explained. At first, a suitable number of sheets of the iron constituting members 3a are laminated for constituting the laminated iron core 3, and then in the punched hole 7 located in the central part thereof, the legs a, 15a of the electrical guiding plate 9 for the primary winding and the central leg 11a of the electric guiding plate 11 for the secondary winding are laminated alternately and in the reverse direction in a suitable number of sheets with intervemience of a suitable insulating plate (not shown). On this insertion, the cut open parts 15b, 15b and 11b, 11b of the both electrical guiding plates 9, 11 are utilized, and it is performed in such a state that the legs 15a, 15a and the central leg 11a are bent up and down by the amount of breadth I (see FIG. 3) of the iron core part relative to the other leg. And the corner part of the laminated winding 5 is fixed in a right position by the fixing implement 19 such as the insulating bar or vis including the insulating tube etc., terminals 150,15d and 11c, 11d are connected suitably for forming the primary and the secondary winding. In this case, of course, laminated iron core 3 and the winding 5 are insulated from each other. For this insulation and theinsulation between each other of said electrical guide plates 9, material 11 can be used such as, for example, glass fiber cloth or themsulating paper; moreover, it may be considered that the conducting plates 9, 11 are previously covered with an insulating resin.

The iron core in the implement of this invention has no seam at all, so that the magnetic circuit becomes the perfect closed circuit, and the magnetic resistance of the iron core decreases remarkably, so that many magnetic fluxes can be obtained by the small magnetomotive force.

Further, the present invention is not limitted by the practical embodiment described above. As shown in FIGS. 6 10, as the second illustrative practical embodiment, the iron core can be constituted by dividing it into several parts. Namely, the transformer 20 of the present embodiment is composed of the first iron core 23, second iron cores 25, 25, third iron cores 27, 27, the laminated iron core 31 including fourth iron core 29, 29, 29 and 29 and the winding including two winding members 33, 33'. The primary iron core 23 of the laminated iron core 31 is, as shown in FIG. 8, (l), composed of a required number of sheets of the constituting member 23a of the continuous thin rectangular iron plate laminated having a central punched rectangular opening 37, while the second iron core 25 is, as shown in FIG. 8, (2), somewhat smaller than said constituent member 23a. The constituent member 25a composed of thin rectangular iron plate of continuous four sides, having a central rectangular hole 39 punched samely sized as said punched hole 37, are laminated for constituting two, and are doubled coaxially before and after said first iron core 23 respectively. Through these two cores are inserted the inner legs 33a, 33a of said two windings 33, 33' in the punched holes 37, 39 for intercrossing simultaneously, and filling about one half of the inner hole 45, 45 of each winding parts 33, 33' of these, the remaining part thereof is formed in ]shaped space. The third iron core 27 is constituted in such a way that, as shown in FIG. 8, the constituent two members 27a of the rectangular iron thin plate having a central punched opening 41 are laminated in same number as the first iron core 23 for constituting two, and the outer legs 33b, 33b of the winding member 33 are inserted respectively in the opening 41 for crossing the winding members 33, 33 respectively. Further, the fourth iron cores 29, as shown in (4) of FIG. 8, are composed of four thin rectangular iron plates 29a having the central opening 43 punched, are laminated, and in such a way that the remaining clearance of said both clearances, namely, fore and aft clearances may be filled, are arranged such that it may abut perpendicular at the fore and rear of the first iron core 23 and the third iron core 27, 27. In said punched holes 43, 43, 43, 43 are inserted and crossed respectively, the lateral legs 33c, 33c, and constituting member pieces 49, 49. Next, winding members 33, 33 have good electrically conductive plate members composed of laminated square plate having central square opening 45, 45. For example, as shown in FIG. 9, three legs, namely, outer leg 33a, transverse leg 33c, and inner leg 33b are connected continuously for forming the U-shaped constituent member 47, and one side 49 closes opening of U-shape. Terminals 51, 51 are projected at each end respectively. Said laminated iron core 31 and the winding part 35 are insulated electrically to each other.

Next, assembling order thereof is explained. At first, winding members 33 are separated for the first winding use and the secondary winding use previously, and the U-shaped member 47 of these are laminated separately, and as shown in FIG. 10, one of these, for example from one end of the U-shaped constituting piece 47 forming the primary member, is inserted successively in the transverse leg 33c the constituting member 29a of the fourth iron core 29 and laminated until the required thickness thereafter, the constituting piece 27a of the third iron core 27 is inserted into the outer leg 33b and laminated to obtain required thickness. On the other hand, iron plates 29a constituting the fourth iron core 29 are consecutively inserted from one end of the U- shaped constituent member 47 constituting the secondary winding into the lateral legs 33c until the predetermined thickness is reached. Thereupon, the constituting member piece 49 as one side of the primary winding and the constituting member piece 49 as one side of the secondary winding are inserted in the lateral leg 330 of the U-shaped constituent member 47 forming the aforesaid secondary winding and the lateral leg 330 of the constituent member 47 forming the aforesaid primary winding, respectively, in such a manner that terminals 51, 51 consecutively projected to alternatively face outwardly are bent and layed upon the leg portion of the constituting member 49 with a suitable insulating means interposed therebetween. The terminals 51 thus bent are subsequently straightened to their initial conditions. The constituting members 23a of the first iron core 23 are then layed one upon another to reach the predetermined overall thickness while, in the fore and aft iron core 25 are coaxially layed one upon another to the given thickness in such a manner as to permit communicationsof the punched openings 37 and 39, respectively. The first and second iron cores 23 and 25 thus constructed receive in the one half portions of the punched openings 37 and 39, respectively, the inner legs 33a of one of the aforementioned U-shaped constituent members 47 and, thereafter, the other U- shaped constituent member 47 is positioned so as to face the precedingly located constituent member 47. The constituting member pieces 49, 49 are then alternately inserted between the preceding constituting member 47 in such a manner as to be in the same layer and, thereupon, integrally formed with each other with an insulating means (not shown) interposed therebetween while the first, second, third and fourth iron cores 23, 25, 27 and 29 are brought to engage with one another in a crosswise fashion. The other winding member 33' adjacent the above-mentioned is manufactured in the like manner as the preceding one and, thus, these terminals 51 and 51 are suitably connected with each other to constitute the primary and thesecondary windings. Since, in the present embodiment, a seamless iron core is divided with different sizes, not only the magnetic reluctance of each iron core is minimized to a considerable extent but the iron portion may have a weight thereof reduced to less than 90 percent of those of the prior art apparatuses of the above described type. This means that the average magnetic'path can be reduced with the resultant improvement of the efficiency of the transformer.

A third illustrative embodiment of the present invention will now be described with reference to FIGS. 11 through 17. Referring to FIGS. 11 and 12, the transformer apparatus of the third embodiment is generally indicated by reference numeral 60 and shown to comprise a main iron core portion 63, a main winding portion 65, auxiliary iron core portions 67 and 67 which intersect horizontally opposing sides of the main winding portion 65, and auxiliary iron core portions 69 and 69 which are wound round the auxiliary iron core portions 67 and 67, respectively.

As shown in FIG. 13, the main iron core portion 63 is made up of a thin iron plate of rectangular seamless configuraiton with four sides thereof continued and constituent members 63a having punched therein common rectangular openings 71 and layed one upon another by a suitable member in the central portion of the iron plate.

The main winding portion 65 includes, as shown in FIG. 15, electrical conducting plates 79 for the primary winding and electrical conducting plates 87 for the secondary winding which are layed alternatingly one upon another with insulating means (not shown) interposed therebetween. The conducting plate 79 for the primary winding is composed of a pair of constituent members 79a which are disposed in a common plane to abut with each other. Each of the constituent members 79a isand 85 disposed at a spacing from slots 83 and 83 as extending outwardly from the inner openings 81 and 81,

respectively. The main iron core portion 63 is disposed to intersect the respective pair of inner openings 73, 73 and 81, 81, thus filling up approximately one half of each inner opening.

The auxiliary iron core portions 67 and 67 are shown in FIG. 14 to comprise constituent members 67a and 67a, respectively, which are laminated one upon another individually. Each of the constituent members is formed of a rectangular thin iron core which has formed centrally thereof a rectangular punched opening 89 and a seam 91 or connection portion. The auxiliary iron core portions thus arranged are disposed to intersect one side of the main winding portion 65, filling up the remaining spacing in the above-mentioned inner openings 73 and 73.

The auxiliary winding portions 69 and 69 are, on the other hand, formed of laminated electrically conductive plates 99 and 99, respectively. Each of the conductive plates is formed of a rectangular highly conductive plate material which has formed in the central portion thereof an inner opening 93 with terminals 97 and 97 disposed at a spacing from a slot extending outwardly of the inner opening 93, as shown in FIG. 17. Each of the inner openings 93 and 93 is intersected by the auxiliary iron core portions 67 and 67, respectively. It may be readily understood that, in this instance, the abovementioned auxiliary iron core portion 67is electrically insulated from the main winding portion 65 and auxiliary winding portion 69 while the auxiliary winding portion is also electrically insulated from the main winding portion 65.

Hereinafter will now be described a sequence for assembly of the above-described apparatus of the third embodiment. To initiate the assembly, a suitable number of constituent members 63a are placed one upon another to constitute the main iron core portion 63. The punched opening 71 of the main iron core portion 63 then receives therein a suitable member of the conducting plates for the primary and the secondary windings, respectively, in alternating order through insulating plates. The constituent members 67a of the auxiliary iron core portion 67 are consecutively inserted in the remaining spacing in the inner openings 73 and 81 of the main winding portion 65 through the seam 91 until a predetermined thickness is reached. Thereupon, the conductive plates 99 are inserted consecutively one by one in the punched opening 89 of the auxiliary iron core portion 67 until a predetermined thickness is reached. Terminals 77 and are then connected with each other in suitable fashion to provide the primary and the secondary windings and, at the same time, terminals 97 and-97 are connected in any desired manner so as to deliver the required electric power.

It may be appreciated that, while a single auxiliary winding is provided to surround the main winding in the above-mentioned third embodiment, a plurality of auxiliary windings may be disposed around the main winding. h

In this embodiment, the inner openings defined in the main winding by the primary and the secondary windings are respectively filled up more than halves thereof by the leg portions of the main iron core portion with the remaining spacings filled up by the leg portions of the auxiliary iron core portion. More specifically, the main winding portion for the supply of large power is wound round the combined iron core portion of the leg portions of the main and auxiliary iron core portions,

respectively, while the auxiliary winding portion for supplying small power is wound round only the leg portion of the auxiliary iron core portion. It follows that the auxiliary winding portion for inducing a small power is wound not on the main winding portion having a large sectional area of the iron core but on the auxiliary iron core portion, which has a far smaller sectional area with the resultant advantage encountered in a reduced number of windings in the auxiliary winding portion. Furthermore, this arrangement can be readily and easily manufactured when compared with the prior art practice wherein a branch line is drawn out from the midway of the secondary winding, thus resulting in a considerably economical transformer.

It should be born in mind that the present invention is not limitted to the foregoing embodiments but various modifications may be applied thereto. For instance, the primary and the secondary windings may be composed of electrically conductive plates all having the same configurations. Further, the effects of the iron core portion arenot diminished even when a wound iron core is used in lieu of the laminated iron core for the iron core portion.

I claim:

1. Transformer apparatus, comprising:

an iron core havingat least one unitary seamless plate member surrounding and defining a core opening;

a pair of electrically conductive windings each of which is proximately of loop configuration;

each said loop forming and defining an inner open:

said winding loops being coplanar, and a portion of each said loop passing through and occupying said core opening;

said winding being electrically insulated from each other to provide a primary winding and a secondary winding, respectively, of the electrical transformer;

each of said pair of windings comprising plural stacked laminate portions each having proximately loop configuration and defining an inner opening within the loop;

the laminate portions of one winding being alternately interlaced with the laminate portions of the other winding of said pair of windings;

each of said winding portions of one winding being electrically insulated from each adjacent laminate portions of the other winding;

all portions of said one winding being electrically interconnected to provide said primary winding, and all portions of said other winding being electrically interconnected to provide said second winding;

said iron core is a first iron core intersecting one side of each of said winding loops, said first iron core occupying a given portion of each one of the inner openings respectively formed in and defined by the loops of said pair of windings, a second iron core positioned fore and aft of said first iron core and coaxially therewith, a third iron core which occupys the remaining portion of the above-mentioned inner openings and intersects the remaining sides of the aforesaid winding loops while being continuous with both opposing ends of said first iron core,

and a fourth iron core being in abutting engagement with the first and third iron cores and at right angles. 2. A transformer, comprising a first iron core having a portion, a pair of electrically conductive winding members, said core portion intersecting one side of each of said pair of winding members, said first iron core occupying a given portion of inner openings formed in each of the winding members, respectively, a second iron core disposed fore and aft of said first iron core and coaxially therewith, a third iron core occupying the remaining portion of the above-mentioned inner openings and intersecting another of the sides of the'aforesaid winding members while being continuous with both ends of the above-mentioned first iron core, and a fourth iron core being in abutting engagement with the first and the second iron cores, respectively, at rightangles thereto, whereby the iron core portion of said transformer comprised by said first, second, third, and fourth iron coresis allowed to be light in weight with a reduced average magnetic path.

3. Transformer apparatus, comprising: a primary winding portion having a plurality of stacked electrically conductive first plate means; a secondary winding portion having a plurality of stacked electrically conductive second plate means; said first plate means being alternately interlaced with and electrically insulated from said second plate means; each of said first plate means comprising a pair of coplanar plates, with each said plate forming a loop and having a loop portion abutting the other plate of said pair; each of said second plate means forming a pair of loops which are respectively aligned with the loops in each of the coplanar plates of said first plate means and which have a common loop portion aligned with said abutting loop portion of said first plate means; amain iron core portion extending around the interlaced abutting loop portions of said first plate means and also extending around the interlaced common loop portions of said second plate means, said main iron core occupying substantially half of each such loop; a pair of auxiliary iron core portions; one of said auxiliary iron core portions extending around one of the interlaced loops of said second plate means and occupying substantially the other half of said oneloop; and

the other of said auxiliary iron core portions extending around the other of the interlaced loops of said second plate means and occupying substantially the other half of said other loop.

4. The transformer as in claim 3, further comprising an auxiliary winding portion extending around one of said auxiliary core portions. 

1. Transformer apparatus, comprising: an iron core having at least one unitary seamless plate member surrounding and defining a core opening; a pair of electrically conductive windings each of which is proximately of loop configuration; each said loop forming and defining an inner opening; said winding loops being coplanar, and a portion of each said loop passing through and occupying said core opening; said winding being electrically insulated from each other to provide a pRimary winding and a secondary winding, respectively, of the electrical transformer; each of said pair of windings comprising plural stacked laminate portions each having proximately loop configuration and defining an inner opening within the loop; the laminate portions of one winding being alternately interlaced with the laminate portions of the other winding of said pair of windings; each of said winding portions of one winding being electrically insulated from each adjacent laminate portions of the other winding; all portions of said one winding being electrically interconnected to provide said primary winding, and all portions of said other winding being electrically interconnected to provide said second winding; said iron core is a first iron core intersecting one side of each of said winding loops, said first iron core occupying a given portion of each one of the inner openings respectively formed in and defined by the loops of said pair of windings, a second iron core positioned fore and aft of said first iron core and coaxially therewith, a third iron core which occupys the remaining portion of the above-mentioned inner openings and intersects the remaining sides of the aforesaid winding loops while being continuous with both opposing ends of said first iron core, and a fourth iron core being in abutting engagement with the first and third iron cores and at right angles.
 2. A transformer, comprising a first iron core having a portion, a pair of electrically conductive winding members, said core portion intersecting one side of each of said pair of winding members, said first iron core occupying a given portion of inner openings formed in each of the winding members, respectively, a second iron core disposed fore and aft of said first iron core and coaxially therewith, a third iron core occupying the remaining portion of the above-mentioned inner openings and intersecting another of the sides of the aforesaid winding members while being continuous with both ends of the above-mentioned first iron core, and a fourth iron core being in abutting engagement with the first and the second iron cores, respectively, at right angles thereto, whereby the iron core portion of said transformer comprised by said first, second, third, and fourth iron cores is allowed to be light in weight with a reduced average magnetic path.
 3. Transformer apparatus, comprising: a primary winding portion having a plurality of stacked electrically conductive first plate means; a secondary winding portion having a plurality of stacked electrically conductive second plate means; said first plate means being alternately interlaced with and electrically insulated from said second plate means; each of said first plate means comprising a pair of coplanar plates, with each said plate forming a loop and having a loop portion abutting the other plate of said pair; each of said second plate means forming a pair of loops which are respectively aligned with the loops in each of the coplanar plates of said first plate means and which have a common loop portion aligned with said abutting loop portion of said first plate means; a main iron core portion extending around the interlaced abutting loop portions of said first plate means and also extending around the interlaced common loop portions of said second plate means, said main iron core occupying substantially half of each such loop; a pair of auxiliary iron core portions; one of said auxiliary iron core portions extending around one of the interlaced loops of said second plate means and occupying substantially the other half of said one loop; and the other of said auxiliary iron core portions extending around the other of the interlaced loops of said second plate means and occupying substantially the other half of said other loop.
 4. The transformer as in claim 3, further comprising an auxiliary winding portion extending around one of said auxiliary core portions. 